U.S. patent application number 16/891044 was filed with the patent office on 2020-09-17 for mobile device cases and case systems with embedded sidewall shock absorber.
This patent application is currently assigned to Incipio, LLC. The applicant listed for this patent is Incipio, LLC. Invention is credited to Andy Fathollahi, Peter Tu.
Application Number | 20200288833 16/891044 |
Document ID | / |
Family ID | 1000004869709 |
Filed Date | 2020-09-17 |
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United States Patent
Application |
20200288833 |
Kind Code |
A1 |
Fathollahi; Andy ; et
al. |
September 17, 2020 |
MOBILE DEVICE CASES AND CASE SYSTEMS WITH EMBEDDED SIDEWALL SHOCK
ABSORBER
Abstract
Protective cases and case systems for a mobile device are
disclosed herein. The cases include a multi component structure
that defines a compartment dimensioned to receive a mobile device
and includes one or more shock absorber elements embedded within
its side walls. The multi-component construct may be configured as
a standalone case or as a sleeve that reversibly fits within
another external component or shell. The shock absorber element may
be formed in multiple segments and may be formed of a softer
material than adjacent regions of the case and co-molded into a
channel in a supporting wall component that is formed of a more
rigid material. The shock absorber component may have one or more
channels formed in its outer surface and may extend internally into
the device compartment to form relatively soft corner pads or
cushions. Some embodiments may further include an optional screen
protector lid.
Inventors: |
Fathollahi; Andy; (Corona
del Mar, CA) ; Tu; Peter; (Long Beach, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Incipio, LLC |
Irvine |
CA |
US |
|
|
Assignee: |
Incipio, LLC
Irvine
CA
|
Family ID: |
1000004869709 |
Appl. No.: |
16/891044 |
Filed: |
June 2, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15208574 |
Jul 12, 2016 |
10667589 |
|
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16891044 |
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62192030 |
Jul 13, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A45C 11/00 20130101;
A45C 2011/002 20130101; A45C 2011/003 20130101 |
International
Class: |
A45C 11/00 20060101
A45C011/00 |
Claims
1. A protective case configured to reversibly receive and retain a
mobile device, said protective case comprising: a first component
configured to receive a mobile device and comprising side walls
having external channels thereon; and a second component co-molded
within said external channels, said second component including one
or more channels on its outer facing surface; wherein said first
component is composed of a first polymer material and said second
component is made of a second polymer material that is different
than said first polymer material, and wherein said second polymer
material is softer than said first polymer material.
2. The protective case of claim 1, wherein said first component
defines a compartment configured to receive said mobile device and
said compartment includes internal corner regions configured to be
in contact with corner regions of said mobile device.
3. The protective case of claim 2, wherein said second component
extends through apertures in said first component to form cushion
pads located at one or more internal corner regions, wherein said
cushion pads are configured to be in contact with said mobile
device when said mobile device is inserted into the first component
of the case.
4. The protective case of claim 1 further comprising a shell
component configured to reversibly receive said first and second
components, said shell component comprising transparent sidewalls
and formed of a material that is more rigid than either said first
or second polymer material.
5. The protective case of claim 1 further comprising a transparent
screen protective lid configured to reversibly snap into and out of
a channel that is formed on said first component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 15/208,574, filed on Jul. 12, 2016, which the
benefit of and priority to U.S. Provisional Patent Application Ser.
No. 62/192,030, filed on Jul. 13, 2015, the entireties of which are
hereby incorporated herein by reference.
BACKGROUND
Field of the Invention
[0002] The present disclosure relates to protective cases for
mobile devices.
Description of the Related Art
[0003] Mobile electronic devices, such as smartphones, tablets,
laptops, and the like, are known to sustain damage from impact and
from contamination as a result of the ingress of water or other
fluids. Such damage may result, for example, in a cracked screen,
scratches on a finished surface, lost or damaged buttons or
controls, cracked or bent external body components, and/or failed
or malfunctioning electrical components. Protective cases can
protect mobile electronic devices from such damage and other types
of damage.
[0004] There is a continuing need for protective cases and case
systems for mobile devices that provide improved protection that
can be readily perceived by a user and incorporated into case
configurations or systems with varying levels of protection.
SUMMARY
[0005] Protective cases and case systems for a mobile device are
disclosed herein. The cases include a multi component structure
that defines a compartment that is dimensioned to receive a mobile
device and includes one or more shock absorber elements embedded
within its side walls. The multi-component construct may be
configured as a standalone case or as a sleeve that reversibly fits
within another external component or shell. The shock absorber
element may be formed in multiple segments and may be formed of a
softer material than adjacent regions of the case and co-molded
into a channel in a supporting wall component that is formed of a
more rigid material. The shock absorber component may have one or
more channels formed in its outer surface and may extend internally
into the device compartment to form relatively soft corner pads or
cushions. When a shell is employed, additional level of protection
to the mobile device may be provided. The shell may have
transparent side walls that allow visibility to the shock absorber
elements so that the user can perceive the protective construction
of the case. A screen protector lid that retentively snaps into and
out of the case or sleeve so as to provide additional protection to
the mobile device is also disclosed herein. The shell may be used
with or without the screen protector lid.
[0006] In some embodiments, the cases have one or more discrete
shock absorber elements integrally molded and embedded into the
external surface of a sidewall of another component that houses the
mobile device and that may be made of a material that is harder
than the material that forms the shock absorber. The shock absorber
may include one or more channels that are formed on its outer
surface. The channels provide space that allows the channel walls
to flex with force and thereby facilitate absorption of the force.
The construct may be in the form of a stand-alone case or a sleeve
configured to be received within another component.
[0007] In some embodiments, the material that forms the shock
absorber element also forms internal corner pads that are capable
of providing additional cushion at the corners of the mobile
device.
[0008] In some embodiments, the case or case system may include a
separate shell component that is configured to reversibly receive a
flexible sleeve, which is configured to house the mobile device and
which includes a molded component that forms the shock absorber
element. The shell component may be composed of transparent
sidewalls that provide visibility to the shock absorber element and
may be formed of a material that is more rigid than the materials
that form the sleeve component.
[0009] In some embodiments, the case or case system may include a
screen protector that reversibly snaps or clips into and out of the
case or sleeve to cover the front face or screen of the mobile
device.
[0010] Numerous configuration and construction aspects of the
various components and their manufacture are also described
herein.
[0011] Each of the foregoing and various aspects, together with
those set forth in the claims and summarized above or otherwise
disclosed herein, including the figures, may be combined without
limitation to form claims for a device, apparatus, system, method
of manufacture, and/or method of use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The figures provided herewith are intended to illustrate but
not to limit the invention. Like reference characters in the
figures denote corresponding features consistently throughout
similar embodiments. Each drawing is generally to scale and hence
relative dimensions of the various layers and components can be
determined from the drawings.
[0013] FIG. 1 illustrates a front face perspective view of a first
embodiment of the disclosed protective case. The embodiment
illustrated is particularly configured for an Apple.RTM.
iPhone.RTM. 6 device.
[0014] FIG. 2 illustrates a front face view of the embodiment shown
in FIG. 1.
[0015] FIG. 3 illustrates a back face view of the embodiment shown
in FIG. 1.
[0016] FIG. 4 illustrates a left side view of the embodiment shown
in FIG. 1.
[0017] FIG. 5 illustrates a right side view of the embodiment shown
in FIG. 1.
[0018] FIG. 6 illustrates a top side view of the embodiment shown
in FIG. 1.
[0019] FIG. 7 illustrates a bottom side view of the embodiment
shown in FIG. 1.
[0020] FIG. 8 illustrates a cross-sectional perspective view taken
along line A-A of the embodiment shown in FIG. 1.
[0021] FIG. 9 illustrates a cross-sectional perspective view taken
along line B-B of the embodiment shown in FIG. 1.
[0022] FIG. 10 illustrates an exploded perspective view of the
components of the embodiment shown in FIG. 1.
[0023] FIG. 11 illustrates an exploded right side view of the
components of the embodiment shown in FIG. 1.
[0024] FIG. 12 illustrates a front face perspective view of a
second embodiment of the disclosed protective case. The embodiment
illustrated is particularly configured for an Apple.RTM.
iPhone.RTM. 6 device.
[0025] FIG. 13 illustrates a front face view of the embodiment
shown in FIG. 12.
[0026] FIG. 14 illustrates a back face view of the embodiment shown
in FIG. 12.
[0027] FIG. 15 illustrates a left side view of the embodiment shown
in FIG. 12.
[0028] FIG. 16 illustrates a right side view of the embodiment
shown in FIG. 12.
[0029] FIG. 17 illustrates a top side view of the embodiment shown
in FIG. 12.
[0030] FIG. 18 illustrates a bottom side view of the embodiment
shown in FIG. 12.
[0031] FIG. 19 illustrates a cross-sectional perspective view taken
along line A-A of the embodiment shown in FIG. 12.
[0032] FIG. 20 illustrates a cross-sectional perspective view taken
along line B-B of the embodiment shown in FIG. 12.
[0033] FIG. 21 illustrates an exploded perspective view of the
components of the embodiment shown in FIG. 12.
[0034] FIG. 22 illustrates an exploded right side view of the
components of the embodiment shown in FIG. 12.
[0035] FIG. 23 illustrates a front face perspective view of a third
embodiment of the disclosed protective case. The embodiment
illustrated is particularly configured for an Apple.RTM.
iPhone.RTM. 6 device.
[0036] FIG. 24 illustrates a front face view of the embodiment
shown in FIG. 23.
[0037] FIG. 25 illustrates a back face view of the embodiment shown
in FIG. 23.
[0038] FIG. 26 illustrates a left side view of the embodiment shown
in FIG. 23.
[0039] FIG. 27 illustrates a right side view of the embodiment
shown in FIG. 23.
[0040] FIG. 28 illustrates a top side view of the embodiment shown
in FIG. 23.
[0041] FIG. 29 illustrates a bottom side view of the embodiment
shown in FIG. 23.
[0042] FIG. 30 illustrates a cross-sectional perspective view taken
along line A-A of the embodiment shown in FIG. 23.
[0043] FIG. 31 illustrates a cross-sectional perspective view taken
along line B-B of the embodiment shown in FIG. 23.
[0044] FIG. 32 illustrates an exploded perspective view of the
components of the embodiment shown in FIG. 23.
[0045] FIG. 33 illustrates an exploded right side view of the
components of the embodiment shown in FIG. 23.
[0046] FIG. 34 illustrates an exploded perspective top face view of
the embodiment shown in FIG. 23 with an iPhone.RTM. 6 disposed
below the lid component.
[0047] FIG. 35 illustrates an exploded perspective bottom face view
of the embodiment shown in FIG. 23 with an iPhone.RTM. 6 disposed
below the lid component.
[0048] FIGS. 36A-36E illustrate isometric cross-section views of
various configurations of the shock absorber component.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0049] Protective cases and case systems for a mobile device are
disclosed herein. The cases include a multi component structure
that defines a compartment that is dimensioned to receive a mobile
device and includes one or more shock absorber elements embedded
within its side walls. The multi-component construct may be
configured as a standalone case or as a sleeve that reversibly fits
within another external component or shell. The shock absorber
element may be formed in multiple segments and may be formed of a
softer material than adjacent regions of the case and co-molded
into a channel in a supporting wall component that is formed of a
more rigid material. The shock absorber component may have one or
more channels formed in its outer surface and may extend internally
into the device compartment to form relatively soft corner pads or
cushions. When a shell is employed, additional level of protection
to the mobile device may be provided. The shell may have
transparent side walls that allow visibility to the shock absorber
elements so that the user can perceive the protective construction
of the case. A screen protector lid that retentively snaps into and
out of the case or sleeve so as to provide additional protection to
the mobile device is also disclosed herein. The shell may be used
with or without the screen protector lid.
[0050] In some embodiments, the cases have one or more discrete
shock absorber elements integrally molded and embedded into the
external surface of a sidewall of another component that houses the
mobile device and that may be made of a material that is harder
than the material that forms the shock absorber. The shock absorber
may include one or more channels that are formed on its outer
surface. The channels provide space that allows the channel walls
to flex with force and thereby facilitate absorption of the force.
The construct may be in the form of a stand-alone case or a sleeve
configured to be received within another component.
[0051] In some embodiments, the material that forms the shock
absorber element also forms internal corner pads that are capable
of providing additional cushion at the corners of the mobile
device.
[0052] In some embodiments, the case or case system may include a
separate shell component that is configured to reversibly receive a
flexible sleeve, which is configured to house the mobile device and
which includes a molded component that forms the shock absorber
element. The shell component may be composed of transparent
sidewalls that provide visibility to the shock absorber element and
may be formed of a material that is more rigid than the materials
that form the sleeve component.
[0053] In some embodiments, the case or case system may include a
screen protector that reversibly snaps or clips into and out of the
case or sleeve to cover the front face or screen of the mobile
device.
[0054] As illustrated in FIGS. 34-35, mobile devices 10 that may be
reversibly secured by the disclosed protective cases and case
systems typically include sides (left 11, right 12, top 13, and
bottom 14), a back face 15 and a front face 16. The sides typically
have one or more user interface ports and buttons (e.g., charging
ports, power buttons, volume buttons, and microphone and speaker
grills). The back face typically includes one or more camera and/or
flash lens and sometimes also includes speakers or microphones and
sometimes also includes touchscreen interfaces. The front face
typically includes one or more touchscreens, optionally a home
button, one or more microphones and/or speakers, a camera lens, and
one or more proximity sensors.
[0055] FIGS. 1-11 illustrate a first embodiment of a protective
case 100 that is generally comprised of a first molded component
110 that defines a compartment that is dimensioned to receive and
protect the mobile device 10 (illustrated in FIGS. 34-35) for which
it is configured, a second molded component 130 in the form of a
shock absorber co-molded within the side walls of the first molded
component 110, and a relatively rigid back face panel 150 that is
co-molded to the bottom perimeter of the first molded component
110.
[0056] The first molded component 110 is formed of a polymer that
is relatively more rigid (or less flexible) than the material that
forms the second molded component 130 but less rigid (or more
flexible) than the material that forms the back face panel 150.
Hence the second molded component 130 is formed of a material that
is the most flexible out of the three components. For example the
first molded component 110 may be formed of thermoplastic
polyurethane (TPU) having a Shore A hardness of 85, the second
molded component 130 may for formed of a thermoplastic elastomer
(TPE) having a Shore A hardness of 65, and the molded back face
panel 150 may be formed of a polycarbonate material having a
hardness that exceeds the other two materials (e.g., Rockwell
hardness of M70). While specific construction materials have been
identified herein, it should be understood that any suitable
polymer, polyurethane, plastic, or thermoplastic elastomer having
suitable properties to allow for the desired flexibility or
elasticity, and preferably also having sufficient durability and
resistance to oil, grease, and abrasion, may be employed.
[0057] As illustrated in FIGS. 1-11, the first molded component 110
is configured to extend around the perimeter of the mobile device
10 and includes inner and outer surfaces 111 and 112, respectively,
which define walls having upper and lower end regions 115 and 116
that are configured to extend from the front face 16 of the device
10 towards the back face 15 of the device 10 with the inner
surfaces of the walls being dimensioned to reside adjacent and
snugly against the sides of the mobile device 10. The inner and
outer surfaces of the first molded component 110 define side walls
(left, right, top, and bottom sidewalls 123a, 123b, 123c, and 123d
of the case 100 that correspond with the left, right, top, and
bottom sides 11, 12, 13, and 14 respectively of the mobile device
10 and extend longitudinally from the corners 122a, 122b, 122c, and
122d that are defined thereby.
[0058] One or more user interface apertures 117a, 117b, 117c, and
117d are provided in the defining walls of the component 110 to
correspond with various user interfaces including the silent switch
17a, the headset jack 17b, the charging/communication port 17c, and
speakers/microphone grill 17d of the device 10. In addition
multiple control buttons 118a, 118b, and 118c, which in the
illustrated embodiment protrusions 119 are provided on the inner
surface 111 and are configured to correspond with various control
buttons on the device including, for example, the + and - volume
control buttons 18a and 18b and the power button 18c. The wall
thickness between the outer and inner surfaces 112 and 111 may be
thinner near the buttons as compared to adjacent or other regions
to allow for additional flexibility by the user.
[0059] The first molded component further includes a projecting
edge or lip 113 that is configured to extend from the upper end
region 115 over the front face 16 of the mobile device 10 so as to
define a major aperture 114 through which the front face 16 and the
touchscreen of the mobile device 10 may be visible to the user when
the device 10 is in the case 100. The lip 113 is configured to
retain the device 10 within the compartment defined by the first
molded component 110, yet also be flexible enough to allow for
insertion and removal of the device 10 into the case 100 through
the major aperture 114. As depicted in the drawings, the lip 113
protrudes around the entire major aperture 114 a uniform distance
as measured from the outer surface 112. It should be understood,
however, that the lip 113 may protrude different distances, less or
more in one or more regions, and may not extend around the entire
perimeter of the major aperture 114, but only partially or in
discrete regions (e.g., one, two, three, or all sides (or portions
thereof) and/or one, two, three, or all four corners).
[0060] The first molded component 110 also includes one or more
channels 120 disposed within its outer surface 112 between the
upper and lower end regions 115 and 116 that extend longitudinally
along one or more of the walls 123a-123d. In the illustrated
embodiments the channels 120 do not extend into the user interface
aperture regions 117a-117d or the regions where the control buttons
118a-118c are provided. It is contemplated, however, that the
channels may be configured to extend into one or more or all of
those regions.
[0061] Retention apertures 121 (best seen in FIGS. 10-11) extending
from the outer surface 112 to the inner surface 111 may also be
provided in the first molded component 110. In the illustrated
embodiment, the retention apertures 121 are positioned within the
channels 120 at each of the four corners 123a-123d. It should be
understood, however, that the apertures 121 may be positioned
elsewhere along the channel 120, for example along one or more of
the sides with or without the corner apertures. As will be
described below, the retention apertures 121 may assist in securing
and retaining the second molded component 130 to the first molded
component 110 when they are co-molded to one another and thereby
reduce the likelihood of the second molded component 130 peeling
off the first molded component 110. This also provides a mechanism
by which force may be transferred from the mobile device housed
within the case.
[0062] The second molded component 130 is co-molded into the
channel 120 of the first molded component 110. It has an inner,
outer, and side surfaces 131, 132, and 133 respectively. The inner
and side surfaces 131 and 133 are in contact with the outer
surfaces 112 of the channel 120 of the first molded component 110.
The outer surface 132 includes one or more channels 134 which
overlie and run longitudinally in parallel with the channel 120
defined in the first molded component 110. In the illustrated
embodiments, the channel 134 is in the form of a "V" as generally
depicted in FIG. 36a. It should be understood that the channel 134,
or portions thereof, may have different cross-sectional
configurations such as those depicted in FIGS. 36b-36e. Such
configurations may include a semi-circle or semi-elliptical
configuration such as that depicted in FIG. 36b, may have multiple
channels 134 that are the same or different in cross-section, that
have the same or different depths, or that are immediately adjacent
to one another or are spaced apart such as those depicted in FIGS.
36c-36e.
[0063] The inner surface 131 of the second molded component 130 is
configured to conform with the corresponding channel 120
configuration of the first molded component 110 and may, as
illustrated, be slightly concave to conform with the outer surface
112 of the channel 120, which in turn corresponds to the curvature
of the sides of the iPhone.RTM. 6 smart phone which it is designed
to house. It should be understood, however, that the outer surface
112 of the channel 120 may be flat or convex or a combination of
different surfaces that may or may not correspond with the side
walls of the mobile device that the case is configured to
house.
[0064] When force is applied to the first molded component 110
(e.g., form impact of drop or the like), the force is transferred
to the second molded component 130 which can absorb and dissipate
the force through the inward and/or outward flexing of the walls
that form channels 120 and 134. Improved protection of the mobile
device may thereby be achieved. The second molded component 130
thereby is capable of serving as a mechanical shock absorber that
is embedded within the sidewalls of the first molded component
110.
[0065] In order to provide improved co-molding adherence and
protection, the second molded component 130 bleeds through the
retention aperture 121 at the corners to form internal corner
bumpers 135. Hence, the second molded component 130 sandwiches the
first molded component 110 at those discrete regions in the corner.
Because the internal corner bumpers 135 are formed of the
relatively softer material that forms the second molded component
130, additional cushioning can be provided to the mobile device at
the corners. This can be important inasmuch as the corners tend to
be the regions that receive the greatest impact force when mobile
devices are dropped or are subject to other impacts.
[0066] As depicted in the illustrated embodiments, the second
molded component 130 corresponds in dimension with the channels 120
of the first molded component 110 and does not extend into the user
interface aperture regions 117a-117d or the regions where the
control buttons 118a-118c are provided. As previously noted,
however, it is contemplated that the channels 120 may be configured
to extend into one or more or all of those regions and hence it is
contemplated that the second molded component 130 will in such
embodiments also extend into those areas to correspond with the
channel 120 regions of the first molded component 110. Also, in the
illustrated embodiments the second molded component 130 is
generally flush or recessed at the channel 134 regions relative to
the outer surface 112 of the first molded component 110.
[0067] It should be understood, however, that the second molded
component 130 may protrude outward in one or more regions beyond
the plane of the outer surface 112 of the first molded component
110. In some preferred embodiments, the second molded component may
be formed of a differently colored material than the first molded
component so that the user or consumer can readily appreciate and
perceive the design features and construction of the protective
cases disclosed herein. Thus, it is contemplated that the first
molded component may be formed of a dark material and the second
molded component may be formed of a lighter material or vice versa.
It is also contemplated that the second molded component may be
formed of strikingly bright, vivid, glowing, or even fluorescent
material as compared to the material that forms the first molded
component.
[0068] In the first embodiment illustrated in FIGS. 1-11, the back
face panel 150 is co-molded to the lower end region 116 at the
bottom perimeter of the first molded component 110. It is formed of
a more rigid polymer, such as polycarbonate. The back face panel
150 is configured to cover the back face 15 of the mobile device 10
and includes one or more additional apertures 151 that are
configured to correspond with functional features of the mobile
device such as the rear camera and flash that are commonly provided
on the back faces of tablets, smart phones, and other mobile
devices. It should be understood that additional apertures may also
be included, such as for example apertures that correspond to other
functional features such as microphones, speakers, and other
touchscreen or interactive screens elements that are positioned on
the back face 15 of the mobile device 10. Thus, while the back face
panel 150 in the illustrated embodiments is configured to cover
nearly all of the back face 15 of the mobile device 10, it should
be understood that the back face panel 150 may only cover discrete
or partial regions of the back face 15 of the mobile device 10.
Indeed, it should be understood that the back face panel 150 may
only cover very small regions, such as perhaps only around the
perimeter of the back face 15 similar in amount to the protruding
edge that forms the lip 113 and thus would leave nearly all of the
back face 15 of the device 10 exposed akin to a protective bumper.
The perimeter regions of the back face panel 150 that mate with the
first molded component 110 may include tabs 152 having reduced
thickness that facilitate adhesion to the co-molded lower end
regions 116 of the first molded component 110.
[0069] The embodiment illustrated in FIGS. 1-11 may be manufactured
via a multi-step injection molding process that may include a
double injection molding process. For example, a first steel mold
is provided that has the shape of the back face panel 150, and
polycarbonate or another suitable material is injected into the
mold and allowed to cool for a suitable period of time. The back
face panel is removed and placed into another mold that is
configured to form the first molded component. A first TPU is
injected into a second mold to form the first molded component 110
co-molded over the tabs 152 of the back face panel 150. The
resulting construct (with or without the second mold) is inserted
into another or third mold that is configured to form the second
molded component 130 and a second TPU material (less rigid and more
flexible than the first TPU material) is injected into the third
mold to form the second molded component 130 that forms the
embedded shock absorber. The first molded component 110 may be
formed for example of a TPU having a Shore hardness of 85 and the
second molded component 130 for example may be formed of a TPE
having a Shore hardness of 65. The back face panel 150 may be
formed, for example, of a PC that has a greater hardness than
either the TPU or TPE material used to form the other components in
the construct. The construct may be printed in one or more regions
to finish the case. For example, pad or tampography printing may be
used to include a black camera ring around the camera/flash
aperture 151.
[0070] FIGS. 12-22 illustrate a second embodiment of a protective
case 200. The second embodiment 200 generally includes the
co-molded first and second molded components 210 and 230 as
previously described in connection with the first and second molded
components of the first embodiment. However, rather than including
a relatively rigid back face panel 150 that is co-molded to the
first molded component 110, the first and second molded components
210 and 230 together form a relatively soft or flexible sleeve 240.
Rigidity in the case is provided by a separate housing or shell 250
that is dimensioned to reversibly receive the relatively soft
sleeve component 240. When the sleeve 240 is secured over the
mobile device 10 and then inserted into the shell 250 it is
configured to fit firmly and snugly within the shell 250 so as to
be retained therein by the force of the shell walls against the
sleeve and hence the against the mobile device 10. The first and
second molded components 210 and 230 have generally the same
features as in the first protective case embodiment 100.
[0071] Namely, the first molded component includes inner and outer
surfaces 111 and 112 that define the left, right, top, and bottom
side walls 123a-123d having upper and lower end regions 115 and
116; edge protrusion or lip 113 that extends inwardly from the
upper end region 115 and defines a major aperture 114; user
interface apertures 117 to facilitate interaction with the user
interfaces (ports and switches and speakers) on the device 10;
control buttons 118a-118c that correspond with the control buttons
18a-18c on the device 10 and corresponding protrusions 119 thereof;
longitudinally extending channels 120 that extend along the
sidewalls; corner retention apertures 121 that facilitate adhesion
and provide additional cushioning at the corner 122a-122d; all as
previously described, with two exceptions.
[0072] First the regions of the sidewalls 123a-123d residing below
the upper end region 115 are configured to be recessed relative to
the upper end region 115 (generally around outer surfaces 112 that
contain the channeled areas 120) so that the upper end regions 115
form an external overhang or edge protrusion 124 that extends
radially outwardly relative to the underlying side walls 123a-123d.
The edge protrusion 124 is dimensioned and configured to reside on
top of the edges of the shell 250 when the sleeve 240 is inserted
into the shell 250. The sidewall regions that are not recessed
(e.g., where the user interfaces 117 and control buttons 118
reside) are configured to snugly fit within corresponding pen-sided
apertures 255 in the sidewalls of the shell 250 so as to further
secure the sleeve 240 within the shell 250.
[0073] Second, the lower end region 116 of the first molded
component 210 is not co-molded to the back face panel as in the
first embodiment. Rather, the lower end region 116 is configured to
extend into and form a continuous flexible back face panel 160,
which includes a honeycomb pattern 161 on its inner surface 111
that is defined by relatively elevated honeycomb patterned walls
162 and recessed surfaces 163 residing within the honeycomb
patterned walls 162. Thus, the back face panel 160 in the second
illustrated embodiment 200 is a unitary extension of the first
molded component 210 thereof as opposed to the discrete component
150 in the first illustrated embodiment 100 that is co-molded to
the first molded component 110 thereof. While the illustrated
embodiments only disclose the honeycomb pattern walls on the inner
surface of the flexible back face panel 160 of the sleeve 240, it
is contemplated that the honeycomb pattern may be formed on the
back side or outer surface 112 of the back face panel 160 or may be
formed on both the inner and outer surfaces 111 and 112 of the back
face panel 160.
[0074] In the illustrated embodiments, the back face panel 160
(like the back face panel 150) is configured to cover the back face
15 of the mobile device 10 and includes one or more additional
apertures 164 that are configured to correspond to functional
features of the mobile device such as the rear camera and flash
that are commonly provided on the back faces of tablets, smart
phones, and other mobile devices. It should be understood that
additional apertures may also be included, such as for example
apertures that correspond to other functional features such as
microphones, speakers, and other touchscreen or interactive screen
elements that are positioned on the back face 15 of the device 10.
Thus, while the flexible back face panel 160 in the illustrated
embodiment is configured to cover nearly all of the back face 15 of
the mobile device 10, it should be understood that the flexible
back face panel 160 may only cover discrete or partial regions of
the back face 15 of the device 10. Indeed, it should be understood
that the flexible back face panel 160 may only cover very small
regions, such as perhaps only around the perimeter of the back face
15 similar in amount to the protruding edge that forms the lip 113
and thus would leave nearly all of the back face 15 of the device
10 exposed akin to a protective bumper. Corresponding apertures in
the flexible back face panel 160 may be formed in the shell 250 to
allow user accessibility to the corresponding features of the
device 10.
[0075] Similarly, the second molded component 230 of the second
embodiment of the protective case 200 includes the same features as
the second molded component 130 of the first embodiment of the
protective case 100. Namely, the second molded component 230
includes the inner and side surfaces 131 and 133 that are in
contact and co-molded to the walls of the channel 120 of the first
molded component 210; an exterior or outer surface 133 that
includes one or more channels 134 formed and extending therein; and
corner bumpers 135 that extend into the mobile device compartment
at the corners 122a-122d via apertures 121 in the first molded
component to form relatively soft internal corner pads that can
provide additional cushioning to the mobile device 10 as previously
described.
[0076] The shell component 250 is configured to surround the sleeve
240 including under the flexible back face panel 160 and along the
sidewalls 123a-123d as illustrated. The shell component 250 thereby
is capable of providing additional rigidity to the assembled case
and protection to the mobile device 10. The shell component 250 is
generally composed of a back face component 257 and left, right,
top, and bottom sidewalls 258a-258d respectively. The back face
component 257 includes one or more apertures 259 that generally
correspond to the apertures 164 on the back face panel 160 of the
first molded component 210 to allow user accessibility to the
features on the back face 15 of the device 10. In addition, the
back face component 257 of the shell 240 includes a honeycomb
pattern 261 on its inner surface 265 that corresponds in
configuration to the honeycomb pattern 161 on the back face panel
160 of the first molded component 210 so that the walls 162 and
recesses 163 overlie and track corresponding walls 262 and recesses
263 that form the honeycomb pattern 261 on the inner surface of the
back face component 257 of the shell 250. The sidewalls 258 include
the open-sided apertures 255 that are configured to snugly receive
the sidewall regions of the first molded component 210 that are not
recessed (e.g., where the user interfaces 117 and control buttons
118 reside) so as to further secure the sleeve 240 within the shell
250. Regions of the shell 250 underlying or adjacent to the
apertures 250 may be strengthened by making those regions thicker
or by incorporating support members across the apertures or
underneath the apertures.
[0077] In the illustrated embodiments, the shell component 250 is
generally formed of two co-molded components 270 and 280. The first
is a relatively rigid or hard panel component 270 formed of PC or
the like that defines the internal side of the back face component
257 and the side walls 258a-258d. The second is a relatively softer
and less rigid cover panel 280 formed of TPU or the like that
covers or caps the outer surface 271 of the panel component 270.
Interlocking honeycomb wall structures 282 extending from the inner
surface 281 of the cover panel 280 extend through the corresponding
recessed regions 263 adjacent walls 262 that form the honeycomb
pattern 261 on the inner surface 265 of the shell 250. The
relatively softer pliable material that forms the cover panel may
deaden impact while the more rigid perimeter panel component
protects the core.
[0078] The embodiment illustrated in FIGS. 12-22 may be
manufactured via a multi-step injection molding process that may
include multiple double injection molding processes. With respect
to the construction of the sleeve 240, for example, a first steel
mold is provided that has the shape of the first molded component
210 including the back face panel 160. TPU or another suitable
material is injected into the mold and allowed to cool for a
suitable period of time. The first molded component 210 is then
placed into another mold or tool that is configured to facilitate
co-molding the second molded component 230 into the channel 120 and
through the apertures 121 of the first molded component 210. A
second TPU or a TPE material (less rigid and more flexible than the
first TPU material) is injected into the second mold or tool to
form the second molded component 230, which includes the embedded
shock absorber and corner cushions or bumpers 135 which together
form the soft flexible sleeve component 240. The resulting sleeve
is removed for inspection and/or finishing. The TPU that forms the
first molded component 210 may have a Shore hardness of 85 and the
TPE that forms the second molded component may be relatively softer
with a Shore hardness of 65.
[0079] With respect the manufacture of the more rigid shell,
another steel mold is provided that is generally shaped like the
rigid panel component 270 including apertures and honeycomb
pattern. PC or the like is injected into the mold and allowed to
cool for a suitable time to form the rigid panel component 270. The
resulting rigid panel component is inserted into another mold that
is configured to co-mold the cover panel 280 over the outer surface
of the rigid panel component 270. A softer TPU or like material is
then injected into the mold to form the cover panel 280 and allowed
to cool for a suitable period. The resulting shell pre-form
construct is removed for inspection and finishing. For example, pad
or tampography printing may be used to include a black camera ring
on the outer surface 266 around the camera/flash aperture 259. The
cover panel 280 may be formed using the same TPU (thus having the
same mechanical properties, e.g., the same Shore hardness and
having the same or a different color) as that used to form the
first molded component 210. It is contemplated, for example, that
the TPU material is opaque and not transparent. The PC material
that forms the relatively more rigid panel component 270 including
the sidewalls 258a-258d of the shell 250 may be formed of a more
transparent or clear material so that a user can see or better
perceive the embedded bumper of the second molded component 230
when the sleeve 240 is inserted into the shell 250. The relatively
more rigid material surrounding the bumper component effectively
acts as a brace such that when the bumper deforms under stress the
bumper pushes on the surrounding more rigidly formed
components.
[0080] In operation, a user inserts the mobile device 10 into the
relatively soft and flexible sleeve 240 via the major aperture 114.
Once inserted, the sleeve 240 (with the mobile device contained
therein) is inserted into the shell 250 so that the protruding side
wall regions in the sleeve are fitted to corresponding open-end
apertures in the shell 250.
[0081] FIGS. 23-35 illustrate a third embodiment of a protective
case 300. The third embodiment 300 is identical to the second
embodiment including the first and second molded components 210 and
230 that form the sleeve 240 and the shell component 250, except it
includes additional protection over the screen or front face of the
device and at the ports. Specifically, the third embodiment
includes a transparent lid or screen protector 390 having a
perimeter profile 391 that clips or fits into a corresponding
channel 392 that is provided on the outer surface of the edge
protrusion or lip 113 of the first molded component 210.
Additionally, the sleeve 240 and in particular the first molded
component 210 is fitted with molded flaps or doors 393 that are
hinged to (or swing from) the upper end region 115 of the first
molded component 210 over user interface apertures 117 such as the
apertures that correspond to the charging/data port and headphone
jack apertures at the bottom side 123c of the case 300. Also, as
illustrated, the sidewalls of the shell may include supporting tabs
394 that are dimensioned to fit between the flaps 393 to provide
additional support and to further seal the device compartment from
debris.
[0082] The lid panel or screen protector 390, as best illustrated
in FIGS. 32-33, is composed of a molded frame 395 that is adhered
to a die cut transparent window 396. The molded frame may, for
example, be formed of PC injected into a mold that is configured to
have the shape of the frame 395. The PC material may be opaque
(e.g., black or a color that matches the first molded component for
example) and may include a recessed region on the inwardly facing
side that is dimensioned to receive and mate with the transparent
window 396. The transparent window may be made of any suitable
material including a glass, tempered glass, or any suitable polymer
such as polyethylene terephthalate ("PET"). When made of a
transparent polymer sheet, like PET, the window may be die cut to
size and adhered via a double sided tape or adhesive to the
inwardly facing recessed region on the frame 395. A jig may be used
to apply pressure between the frame 395 and the window 396 to
assure sufficient adherence there-between. One or more apertures
397 may be formed in the screen protector 390 to facilitate user
interactions with the mobile device such as the home button,
proximity sensors, speakers, and front facing camera features. The
screen protector 390 is configured to be readily attached and
detached by the user.
[0083] In operation, like the second embodiment, the user inserts
the mobile device 10 into the relatively soft and flexible sleeve
240 via the major aperture 114. Once inserted, the sleeve 240 (with
the mobile device contained therein) may be inserted into the shell
250 so that the protruding side wall regions in the sleeve are
fitted to corresponding open-end apertures in the shell 250. The
lid or screen protector 390 may be clipped or snapped into the
channel 392 that is formed in the first molded component 210,
either before or after the sleeve 240 is inserted into the shell
250.
[0084] While the illustrated embodiment illustrates a configuration
in which the perimeter profile 391 transparent lid or screen
protector 390 clips or fits into a corresponding channel 392 that
is provided on the outer surface of the edge protrusion or lip 113
of the first molded component 210, it should be understood that the
channel 392 be may be provided on the top edges of the wall of the
shell 250 and the lid/screen protector 390 would then clip/snap or
be otherwise be attached to the shell 250 as opposed to only the
sleeve 240. Similarly it should be understood that the lid/screen
protector 390 may have multiple protrusions at its perimeters that
allow for attachment to channels in both the shell 250 and the
sleeve 240.
[0085] The previous description of the disclosed embodiments is
provided to enable any person skilled in the art to make or use the
invention disclosed herein. Although the various inventive aspects
are disclosed in the context of certain illustrated embodiments,
implementations, and examples, it should be understood by those
skilled in the art that the invention extends beyond the
specifically disclosed embodiments to other alternative embodiments
and/or uses of the invention and obvious modifications and
equivalents thereof. In addition, while a number of variations of
various inventive aspects have been shown and described in detail,
other modifications that are within their scope will be readily
apparent to those skilled in the art based upon reviewing this
disclosure. It should be also understood that the scope of this
disclosure includes the various combinations or sub-combinations of
the specific features and aspects of the embodiments disclosed
herein, such that the various features, modes of implementation,
and aspects of the disclosed subject matter may be combined with or
substituted for one another. The generic principles defined herein
may be applied to other embodiments without departing from the
spirit or scope of the disclosure. Thus, the present disclosure is
not intended to be limited to the embodiments shown herein but is
to be accorded the widest scope consistent with the principles and
novel features disclosed herein.
[0086] Similarly, the disclosure is not to be interpreted as
reflecting an intent that any claim set forth below requires more
features than are expressly recited in that claim. Rather, as the
following claims reflect, inventive aspects may reside in a
combination of fewer than all features of any single foregoing
disclosed embodiment.
[0087] Each of the foregoing and various aspects, together with
those set forth in the claims and summarized above or otherwise
disclosed herein, including the figures, may be combined without
limitation to form claims for a device, apparatus, system, method
of manufacture, and/or method of use.
[0088] All references cited herein are hereby expressly
incorporated by reference.
* * * * *